Results of implementing the TOC solution for managing projects

Realization Proyects
ABB AG, Power Technologies Division
Electrical Power Transmission, Engineer-to-Order
Before
After
Throughput was 300 bays per year.
Throughput increased to 430 bays per year.

 

Action Park
Theme Park Design, Install and Commissioning
Before
After
121 projects completed in 2004.
142 projects completed in 2005. 153 projects completed in 2006.

 

Airgo Networks
Next Generation Wireless Technology Product Development
Before
After
Cycle time from first silicon to production for 1st generation was 19 months.
Cycle time from first silicon to production for 2nd generation was 8 months.

 

Alcatel-Lucent
Telecomm Switches Design,
Before
After
300 to 400 active projects with 30+ deliveries a month. Lead times were long. On-time delivery was poor.
Throughput was higher by 45% per person. Lead times are 10-25% shorter. 90+% on-time delivery.

 

Alna Software
Customized Software Development
Before
After
Throughput was stagnant for 3 years.
Throughput increased by 14% in first 6 months. Cycle time reduced by 25% and project completions increased 17% with 100% on-time delivery.

 

BHP Billiton
Iron Ore Asset Development Projects
Before
After
25,800 man-hours of engineering design work had to be completed in 8 months. Historical delays of 2 weeks and man-hour overruns of 20%.
Project was finished 3 weeks early. Productivity increased by 25% with only 19,500 man-hours needed.

 

Boeing Space & Intelligence Systems
Satellite Design and Assembly
Before
After
Antenna Assembly and Test was the constraint of the Satellite.
Antenna Assembly and Test was no longer the constraint of the Satellite. Productivity increased by 64% on the next Satellite and a further 26% on the subsequent Satellite.

 

Celsa Group
IT Projects
Before
After
15 SAP functionality projects were completed per month.
SAP functionality project completions increased by 30% to 20 projects a month.

 

Central Nuclear Almaraz Trillo
Nuclear Power Engineering
Before
After
19 design evaluation and modification projects were completed per month.
Throughput increased by 25% to 24-30 projects per month.

 

Chrysler
Automotive Product Development
Before
After
Cycle time for prototype builds was 10 weeks.
Cycle time for prototype builds is 8 weeks. Delivery date performance increased by 83 % with much less fire fighting.

 

Danisco (Genencor)
Biotechnology Plant Engineering
Before
After
20% projects on time.
87% projects on time. 15% immediate increase in throughput.

 

Delta Air Lines, Inc.
Engine Repair & Overhaul
Before
After
Produced 40 engines per month. 4 weeks piece part cycle time.
Increased production by 23% (50+ engines/month), 16%-26% reduction in engine turnaround time. 2.5 weeks piece part cycle time, 25% increase in piece part throughput.

 

eircom, Ireland
Telecommunications Network Design and Installation
Before
After
On-time delivery less than 75%. Average cycle time was 70 days.
Increased on-time delivery to 98+%. Average cycle time dropped to 30 days.

 

Erickson Air-Crane
Helicopter Manufacturing and Maintenance
Before
After
Projects were constantly delayed with only 33% projects completed on-time.
Projects completed on-time increased to 83%.

 

Genencor
Biotechnology Plant Engineering
Before
After
20% projects on time.
87% projects slated to complete on time, with approximately 15% immediate increase in throughput.

 

Hamilton Beach/ Proctor-Silex
New Product Development for Home Appliances
Before
After
34 new products per year. 74% projects on time.
Increased throughput to 52 new products in 1st year, and to 70+ in 2nd year, with no increase in headcount. 88% projects on time.

 

HP Digital Camera Group
High Tech New Product Development
Before
After
6 cameras launched in 2004. 1 camera launched in the spring window. 1 out of 6 cameras launched on time.
15 cameras launched in 2005, with 25% lower R&D expenses. 7 cameras launched in the spring window. All 15 cameras launched on time.

 

LeTourneau Technologies, Inc.
Oil & Gas Platform Design & Manufacturing
Before
After
Design Engineering took 15 months. Production Engineering took 9 months. Fabrication and Assembly took 8 months.
Design Engineering takes 9 months (35% less cycle time). Production Engineering takes 5 months (44% less cycle time). Fabrication and Assembly takes 5 months (38% less cycle time) with 22% improvement in labor productivity.

 

LSI Logic
ASIC Design Technology Development
Before
After
74% projects on time for small projects; major tool releases were late.
Due-date performance increased to 85% projects on time; major tools released on time for three years in a row.

 

Lucent Technologies
Design, Development and Upgrades of Telecommunication Switches
Before
After
Long lead times; Poor on-time delivery
300 to 400 active projects with 30+ deliveries a month. Cycle times are 10 to 25% shorter while throughput per person higher by 45%.

 

Marketing Architects
Advertising Product Development
Before
After
Completed 7 projects in 2006.
Completed 7 projects in 8 months of 2007.

 

Medtronic, Europe
High Tech Medical Product Development
Before
After
Device projects took 18 months on average and were unpredictable.
Development cycle time reduced to 9 months. On-time delivery increased to 90%.

 

Oregon Freeze Dry
Food Preparation and Packaging
Before
After
72 sales projects completed per year.
171 sales projects completed per year. 52% increase in throughput dollars.

 

Rapid Solutions Group
Marketing/Publishing Support
Before
After
Projects were always late. Lead times were not acceptable.
On-time delivery improved by 30%. Lead times were reduced by 25%.

 

Skye Group
Garment Design
Before
After
Product ranges were late to market.
100% due-date performance. 30% reduction in lead times and sampling costs.

 

TATA Steel
Steel Plant Maintenance
Before
After
Boiler Conversion projects took 300-500 days.
Cycle times were reduced to between 120-160 days. Saving of $13.4 million.

 

TECNOBIT
Defense Products Design and Manufacturing
Before
After
Difficult to synchronize Design and Manufacturing. Long project cycle times with frequent delays.
Project cycle times were reduced by 20%.

 

ThyssenKrupp (Johann A. Krause)
Automotive Assembly Systems. Engineer-to-Order. Projects vary from large fully automated assembly lines to small retooling projects.
Before
After
70% of projects were late. High overtime and outsourcing.
Lateness reduced by 50%. 63% productivity gain. 15% more projects completed.

 

US Air Force Operational Test & Evaluation Center
Warfighter Systems Testing
Before
After
18 projects in six months. On time delivery unknown.
26 projects in six months. 75% projects on time; 30% reduction in cycle time.

 

US Air Force Operational Test & Evaluation Center
Warfighter Systems Testing
Before
After
Long cycle times. Low utilization of resources. Poor visibility on project slips.
30% reduction in cycle time measured over 900 projects. 30% improvement in resource utilization. 88% on-time delivery performance.

 

US Air Force, Ogden Air Logistics Center, C130 Production Line
Aircraft Repair & Overhaul
Before
After
21-24 aircrafts on station.
Reduced to 18 aircrafts on station. 25 out of 26 aircrafts delivered on-time or early. (Accumulated 191 days of early delivery in 6 months total)

 

US Air Force, Oklahoma City Air Logistics Center, B-1 Bomber Line
Aircraft Repair & Overhaul
Before
After
Turnaround time 162 days. 7 aircrafts in repair cycle.
Turnaround time reduced to 115 days. 4 aircrafts in repair cycle (3 returned to customer). Production output increased from 185 hours/day to 273. 1 1/2 dock spaces freed up.

 

US Air Force, Warner Robins Air Logistics Center, C5 Production Line
Aircraft Repair & Overhaul
Before
After
Turn around time (TAT) 240 days. 13 aircrafts in repair cycle.
Turn around time (TAT) 160 days. 7 aircrafts in repair cycle.

 

US Marine Corps Logistics Base, Barstow, CA
Aircraft Repair & Overhaul
Before
After
Repair cycle time (RCT) for MK48 was 168 days. RCT for LAV25 was 180 days. RCT for MK14 was 152 days. RCT for LAVAT was 182 days.
Repair cycle time (RCT) for MK48 is 82 days. RCT for LAV25 is 124 days. RCT for MK14 is 59 days. RCT for LAVAT is 122 days.

 

US Naval Aviation Depot, Cherry Point
Aircraft Repair and Overhaul
Before
After
Average turnaround time (TAT) for H-46 aircrafts was 225 days. Average turnaround time (TAT) for H-53 aircrafts was 310 days; throughput was 23 per year.
Reduced H-46 turnaround time to 167 days, while work scope was increasing. Reduced H-53 turnaround time to 180 days. Delivered 23 aircrafts in 6 months; throughput of 46 per year.

 

US Naval Shipyard, Pearl Harbor
Submarine Maintenance and Repair
Before
After
Job Completion Rate = 94%. On-time delivery less than 60%. Cost per job was $5,043.
Job Completion Rate increased to 98%. Increased on-time delivery to 95+%. Reduced cost per job to $3,355, a 33% reduction. Overtime dropped by 49%, a $9M saving in the 1st year.

 

Valley Cabinet Works
Custom Furniture Design and Manufacturing
Before
After
Struggled to complete 200 custom furniture projects per year. Revenues were flat and business was just breaking even. A lot of firefighting in execution.
Completed 334 projects in 9 months. Revenues increased 88% and profits increased by 300% in the first year. Firefighting and thrashing eliminated.